university of pennsylvania introduction to...
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Introduction to Robotics
University of Pennsylvania 1
Introduction to Robotics
Vijay KumarUniversity of Pennsylvania
Philadelphia, PA
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Introduction to Robotics
University of Pennsylvania 2
Outline
� What is Robotics
� Why Robotics
� History
� State of the Art
� Current Research
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Introduction to Robotics
University of Pennsylvania 3
What is a robot?� Webster
An automatic apparatus or device that performs functions ordinarily ascribed to humans or operates with what appears to be almost human intelligence.
� Robotics Institute of AmericaA robot is a reprogrammable multifunctional manipulator designed to
move material, parts, tools or specialized devices through variable programmed motions for the performance of a variety of tasks.
� Hollywood
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Introduction to Robotics
University of Pennsylvania 4
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Introduction to Robotics
University of Pennsylvania 5
Which is the better definition? � Robotics Institute of America
A robot is a reprogrammable, multifunctional, manipulator designed to move material, parts, tools or specialized devices through variable programmed motions for the performance of a variety of tasks.
� WebsterA robot is an automatic apparatus or device that performs functions ordinarily ascribed to humans or operates with what appears to be almost human intelligence.
� Hollywood
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Introduction to Robotics
University of Pennsylvania 6
Human perception and controlVisual system
Posterior parietal cortex
Motor cortex
Motor neurons
Muscles
Limb
Sensors, frame grabbers
Processing, task recognition,
decomposition
Servo controller
Actuators
Mechanical linkage
Planner
VISUO-MOTORGOAL
MOVEMENT GOAL, MOTOR COMMAND
MUSCLE COMMAND, CONTROL SIGNAL
PROPRIO-CEPTIVE
FEEDBACK
VISUALFEEDBACK
POTENTIALS, ELECTRIC CURRENT
FORCES, TORQUES
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Introduction to Robotics
University of Pennsylvania 7
Why Robotics?
Automation in � Manufacturing� Service
Why Automation?
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Introduction to Robotics
University of Pennsylvania 8
Reasons for AutomationShortage of labor
� The ratio of the number of workers to the number of retirees in the U.S. is expected to be 2 to 1 in 2000. Main reason in Japan.
High cost of labor� Low wages are also accompanied by lower productivity
[U.N. study comparing wages and productivity]� In 1990, hourly wages in Malaysia were approx. 15% of that of the U.S. Hourly
productivity was also comparable.� Labor costs are rising Country 1985 1995
Germany 9.6 31.88Japan 6.34 23.66France 7.52 19.34USA 13.01 17.20UK 6.27 13.17
Malaysia 1.08 1.59South Korea 1.23 7.40
China 0.19 0.25India 0.35 0.25
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Introduction to Robotics
University of Pennsylvania 9
Reasons for AutomationIncreased productivity
� value of output per person per hour increases
Lower costs� reduced scrap rate� lower in-process inventory� superior quality� superior quality� shorter (compact) lines
Reducing manufacturing lead time� respond quickly to the consumers’ needs� rapid response to changes in design
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University of Pennsylvania 10
Reasons for AutomationCompetition
� lower prices, better products� better image� better labor relations
Safety
Potential for mass customization
New process technologies require automation
� e.g., robot controlled thermal spray torch for coating engine blocks with atomized steel particles
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University of Pennsylvania 11
Need Automation Even in Low-Wage Countries
Capital intensity is equally high� Fiat plant at Belo Horizonte, Brazil� Carplastic - manufacturer of car plastic components
Ford subsidiary in Monterrey Mexico
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Introduction to Robotics
University of Pennsylvania 12
Case study: CARPLASTIC
A wholly-owned Ford subsidiary in Monterrey, MexicoProducts
� headlamps, polycarbonate instrument panels, radiator grill, consolesProduction
� 1800 pieces/day, failures 10-15 parts per million � main process is injection molding
� 200-4000 ton machines (Engel, Cincinnati Milacron, Huskies)� largest product is 6 kg. Expedition instrument panel (shot size 12 kg)� cycle-time 1 min to 1 min 45 secs.
� abrasive water-jet cutting� 200 workers, $1-2/hour
� compare with $17/hour in the US, $6/hour in Brazil)
� reasonably automated� material handling is not automated, main processes are automated (no option)
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Introduction to Robotics
University of Pennsylvania 13
Case study: CARPLASTIC
Question:Can highly automated facilities be maintained and upgraded in “low-wage countries”?
� Hi-tech machinery maintenance and repair� Quality control, process control requires sophistication� Material handling costs versus other manufacturing costs
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University of Pennsylvania 14
Robotics
Types of AutomationFixed automation
custom-engineered, special-purpose equipment to automate a fixed sequence of operations� high production rates, inflexible product design
Programmable automationequipment designed to accommodate a specific class of product changes� batch production, medium volume
Flexible automationdesigned to manufacture a variety of products or parts� low production rates, varying product design and demand
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University of Pennsylvania 15
History: Fixed Automation� Eli Whitney, pioneer of mass production
Contracted to make 10,000 muskets in 28 months (1798, factory at New Haven). � Machines for producing interchangeable parts� Reduced skills required of operators, increased production rates� Assembly work was simplified
� Oliver Evans, automated “conveying” (1793)� Automated flour mill
� Elihu RootColt six-shooters (1849)� Divide the work and multiply the output� Assembly was reduced to short and simple unit operations which required very
little worker training and high efficiencies could be obtained.
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University of Pennsylvania 16
Gillette South Boston PlantSensor Excel Cartridges
1.5 to 2 billion cartridges/year100 cartridges/minute/line
� Major processes:� injection molding
� 500 ton, 32 cavity molds ($ 1M) machines, 20 second cycle time� extrusion� others: grinding, stamping, welding, assembly� bottlenecks in assembly: injection molding and part feeding
Time to market: 24 monthsCapital cost: $200 millionEstimated life cycle: 6-8 years
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University of Pennsylvania 17
Flexible Automation
Cars, motor cycles13 months from design to production
Group technology
Drug Discovery
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University of Pennsylvania 18
Reasons for not automating� Labor resistance� Cost of upgraded labor
� Chrysler Detroit plant - 1 million hours of retraining� GM Wilmington assembly plant - $250 hours/person/year
� Initial investment� Management of process improvements
� Intellectual assets versus technological assets� Toyota versus Ford study
� Appropriate use of technology� A systems approach to automation is important� Equipment incompatibilities
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University of Pennsylvania 19
Case study: Toyota versus FordToyota Georgetown Plant �Camry/Avalon�20 models�2 lines, 2 platforms/line�Workforce
� 25% college grads� 50% entered college
�Flexible automation� 20 models, 197,000 cars/year� 39,000 specifications � 23,000 one-of-a-kind specifications
Ford Atlanta Plant�Taurus�2 models�2 lines, 1 platform/line�Workforce
� 50% high school drop outs
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University of Pennsylvania 20
Cost of Flexible AutomationCapital costs per car (1996)
Toyota� 480,000 cars/year, $3960/car
Nissan� 450,000 cars/year, $2670/car
Honda� 610,000 cars/year, $3300/year
Suzuki� 200,000 cars/year, $2150/year
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University of Pennsylvania 21
HistoryOrigin of the word “robot”
� Czech word “robotnik”� 1920 play by Karel Capek � 1940s - Isaac Asimov’s science fiction
History of automation� Industrial revolution (late 18th century)� Mechanical looms
� Jacquard looms � Programmable looms
� Crane with motorized grippers (1892)� Mechanical arm for spray painting (1938)� Telecheric/teleoperators (World War II)� First industrial robot (1961)
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University of Pennsylvania 22
Chinese Drawloom
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University of Pennsylvania 23
Swedish Loom (1872)
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University of Pennsylvania 24
Electronic Numerical Integrator and Computer (1946)
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University of Pennsylvania 25
HistoryAdvent of computers
� First large scale electronic computer (1946)� Eniac (University of Pennsylvania)� Whirlwind (MIT)
� Numerically controlled machine tool (1952)� Robot with playback memory (1954)� First industrial robot (1962)
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University of Pennsylvania 26
History: Industrial Robots
GM and Robotics
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University of Pennsylvania 27
History: ResearchWalking robots
� GE walking machine (1967)� Odetics’ Hexapod (1983)� Adaptive Suspension Vehicle (1985)� Ambler (1993)� Honda Humanoid (1997)
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University of Pennsylvania 28
Adaptive Suspension Vehicle (1987)
� 3500 kgs, 500 kg payload� powered by a 550 cc 75 hp Kawasaki engine� 19 8086-based controllers
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University of Pennsylvania 29
The Honda Humanoid (1997)P3-Clip2
Honda_P3_3.mov
Honda_p3.mov
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University of Pennsylvania 30
State of the artIndustrial robotics
� $ 2 billion industry in the U.S. (1999)� $5.3 billion industry world wide (1997)� 15% growth rate (1997 - )
Robotics is a much bigger industry� entertainment� military/space technology� appliances
70 Industrial robots per human worker entering the US labor force in 2000.
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University of Pennsylvania 31
Service RobotsPutzmeister
Honda
CRASAR/iRobotSearch and Rescue
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University of Pennsylvania 32
Robots for Assistive Technology
Raptor
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University of Pennsylvania 33
Service Robots
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University of Pennsylvania 34
What is a robot?Definition of a robot revisited
� manipulate objects in the physical world� compare this to a PC manipulating data
� sense information about the physical world� make decisions based on available information or ask for additional
information� interface in a “friendly”manner with humans� mimic humans� reprogrammable by humans � safe
� Asimov’s laws of robotics
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University of Pennsylvania 35
ApplicationsApplication in 4D environments� dangerous� dirty� dull� difficult
4A tasks� automation� augmentation� assistance� autonomous
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University of Pennsylvania 36
Challenges
Automation
Aut
onom
y
PARTFEEDER
INDUSTRIALROBOT
LAWNMOWER
AGV
IT has had a greaterimpact on automation than on autonomy
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University of Pennsylvania 37
Applications: 1. Biotechnology
� Sequencing Projects
� Research in gene expression� RNA expression� Protein interaction� Antibody library assays
� Combinatorial chemistry� New compounds
� High throughput screening� Targets that can be “hit”
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University of Pennsylvania 38
Biotechnology: SequencingReduction of time and labor intensive DNA/RNA processing and analysis methods� Automation in cell assays� DNA amplification and purification� Plate management� Electrophoresis and quantitative imaging
Hardware� robotic arms, automated turntables and storage systems � pipettors� chromatography devices� thermal cyclers � imaging and detection systems
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University of Pennsylvania 39
Microarray Techniques
A. 100 glass substratesB. Two multi-well plates and blot padC. Arm to deliver plates and de-lidD. 72 plate hotelE. Printing pinsF. Sonicator bathG. Rinse stationH. Drying station
A
B
CD
E
FG
H
Courtesy: J. Gregg and D. Baldwin
OmniGrid from GeneMachines
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University of Pennsylvania 40
Biotechnology: HTS
Compounds
Number of Targets
O
O
N
NN
O
NN O
OH
O
O O
O
O
O
OO
O O
O
NO
N
NN S
O
N+ O
O
NN
O
>106
20 / month
A+B =AB
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University of Pennsylvania 41
ELISA: Enzyme-Linked Immunosorbent Assay
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University of Pennsylvania 42
Bead-Based Assays
Locator
Bead Mixer
Shakers
Washer/Filtration
384, 96 well plates
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University of Pennsylvania 43
What goes where?Variety of block designs/layoutsVariety of reaction protocolsAnalysis protocols
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University of Pennsylvania 44
007
Robotic Sample Processor
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014
HTS: Sample Handling
MOL BANK™ plate storage unit
Handling samples
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University of Pennsylvania 46
Automated analysis
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University of Pennsylvania 47
Liquid Handling Systems
12.5ul with 384 well plates
384 pin adapters
TekCel PlateServerTM
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Cold Store
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Defrost Oven Feeder
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Liquid Handling Cell
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2. Military applications
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3. Space RoboticsHuman operators on earth can control partially autonomous vehicles and manipulators on distant planets
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Space Robotics
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4. Entertainment IndustryEntertainment robot is more'byte' than bark (CNN)Sony AIBO
Honda ASIMO
Disney Robots
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5. Personal Robots?
http://www.personalrobots.com
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Domestic Companions?
Cog, MIT AI Lab
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True Potential: 4D to 3A4D tasks
� dangerous� dirty� dull� dumb
Just as the personal computer is used for automated information management even in households, robots can be used to execute domestic tasks. � Manipulation of bits of information (PC)� Manipulation of physical objects (PR)
AutomationA
uton
omy
Augmen
tation